Introduction Dan Swenson

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2 Introduction Dan Swenson Started with Total Tool In December of 1991 Performed 1000 s of sling, hardware and crane inspections GM of our overhead crane division for 15years Design of cranes, runways, custom lifting beams NOT a PE Commonly perform lift planning and specification rigging Performed rigging and OH crane safety training Received countless hours of safety training

3 Introduction Total Tool Supply Inc. Started In 1977 Purchased SafeWay Sling in Locations Operate 4 Rigging Shops Produce over 150,000 rigging assemblies annually Provide Qualified Rigger and Signal Person Training

4 Disclaimer for Total Tool Rigging & Lifting Safety Education The information contained herein is for informational purposes and is intended for attendees of Total Tool Supply, Inc s rigging and lifting safety seminars only. Reproduction or dissemination of this document without Total Tool s written consent is prohibited. Total Tool assumes no legal responsibility (including, but not limited to incidental or consequential damages) for the information contained herein. Conforming to good safety practices is the responsibility of the rigging gear owner/user and its operating personnel. Total Tool has no direct involvement or control over the owner s or user s use, operation or application of rigging gear. It is the responsibility of the rigging gear owner/user to establish programs to train and designate operators and to train and designate inspection and maintenance personnel.

5 Rigging for Safety Professionals Introduction Applicable Standards General Concepts and Examples Discussion of: Slings Below the Hook Lifters Manual Hoists/Power Hoists Overhead Cranes Monorails, Jib Cranes

6 Safety Share Rigging Follies

7 Mitigate The Danger What we can control Training Inspections Proper storage Proper equipment Proper maintenance Lift Planning Know the weight of your load Provide the correct rigging gear

8 Improper Rigging Technique Suspect Hardware Incorrect Direction of Pull on Eye Bolt Eye Bolt Not Seated

9 Pick Point Must Be Able To Support Load

10 Improper Storage

11 Proper Daily Inspection Would/Should Catch This

12 Proper Maintenance

13 Stats An OSHA 1988 staticall summary of 1000 crane accidents showed poor rigging or slings to be the cause in 34% of the cases Statistics show that nearly 20 people died in 2012 as a result of accidents with overhead hoists. That s because the loads being lifted by overhead hoists tend to be fairly heavy and cause serious damage if dropped. Slings and attachments that aren t secured properly can be a major safety hazard, and when objects begin to slip, they will eventually crash to the floor below.

14 Costs Web Slings 2IN x 6ft TWO PLY EYE&EYE WEB SLING $15 -$20 - EE2902X6 1IN x 6ft TWO PLY EYE&EYE WEB SLING $10-$13 - EE1902X6 2IN x 20ft TWO PLY EYE&EYE SLING $50, EE2902X20

15 Costs Wire Rope Slings 3/8IN x 6ft Wire Rope Sling $15-$ ton (3,200 LBS) 1/2IN x 6ft Wire Rope Sling $18-$ ton (5,600 LBS)

16 Yet Some Times it s treated Like Gold!

17 Applicable Standards OSHA Regulations are the LAW ASME / ANSI rules are created by industryleading authorities AWRF, WSTDA In a court of law they can be just as binding as OSHA When OSHA and ASME vary, it is prudent to follow the most stringent to protect employees

18 Applicable Standards In cases where OSHA doesn t have anything written they will use the General Duty Clause Reference ASME as a: National Consensus Standard Excerpt from OSHA Interpretation Letter While OSHA as yet has no standard of its own covering monorail systems and underhung cranes, under Section 5(a)(1) (the general duty clause) of the Occupational Safety and Health Act all employers have a legal responsibility to provide safe and healthful workplaces for their employees. OSHA's policy is that the general duty clause requires employers to comply with safety standards recognized in the industry, such as ANSI B30.11

19 Applicable Standards Rigging OSHA General Industry Slings Construction Rigging / Slings ASME ASME B30 series of standards: B30.9 Slings B30.10 Hooks B30.20 Below the Hook Lifters (Beams, Clamps, etc.) B30.26 Rigging Hardware

20 Applicable Standards OH Cranes and Hoists OSHA General Industry Overhead and Gantry Cranes Construction Overhead hoists (Lever, Manual Chain, Electric Chain/Wire Rope Hoists) ASME ASME B30 series of standards: B30.2 OH Cranes Top Running B30.11 Monorails Underhung Cranes B30.16 Overhead Hoists Underhung B30.17 Cranes & Monorails - Underhung B30.21 Lever Hoists

21 Applicable Standards Key Point As relates to: Jib Cranes Monorail Cranes Electric Hoists Manual Hoists OSHA SAYS VERY LITTLE General duty clause Based on ASME B30 series of standards National Consensus Standard Overhead Hoists Follow Manufactures Recommendations

22 Applicable Standards

23 Inspection Inspection IS ABSOLUTELY KEY Pre-Use Annual / Documented(?) OSHA & ASME agree that anything used for lifting requires a pre-use pre/shift inspection Common sense says: To perform a proper inspection you have to know what to look for - Training You cant make a safe pick with unsafe rigging gear

24 Do I need to Document Annual Inspections?

25 Visual Inspections 20% Fact 80% Hope On just about any type of sling you can only see about 20% of the load bearing material. This DOESN T mean inspections are hopeless or useless, we simply need to take this fact into consideration when performing inspections.

26 Fact Hope Fact Hope

27 Visual Inspections Experience Counts If it looks that bad on the outside what does it look like inside?

28 Tags All slings MUST BE TAGGED All Below Hook Lifters Must be Tagged All hoisting equipment must be tagged Tags must be legible Including warning label LOGIC How can you do a safe pick if you don t know the capacity of the rigging gear!

29 Tags In General Capacity (s) Type of Material Many Different Types of Webbing and wire rope Serial Number Required by OSHA on Chain Slings GOOD idea on all other types of slings Manufacturer Must be Legible! Including the warning

30 A Word On Safety Factors Generally speaking for rigging the required safety factor is 5:1 A sling rated at 1000lb capacity will break at 5000lbs MINIMUM when new. Purpose Environment Mishaps Shock loading What You Can t See When Inspecting NOT to be considered part of WLL

31 Rigging / Sling Selection Guide

32 Synthetics Advantages Light Easy to rig Low cost Reduces damage to load Strength to weight ratio Disadvantages Low heat resistance(194 degrees max) Subject to cuts, tears and abrasion Subject to chemical degradation UV Dirt Not repairable Consumable Item!

33 Limitations of Synthetic Slings

34 Have you seen this chart before? After Seeing those videos what to you think of it?

35 Round Sling Construction

36 Round Sling Advantages Over Web More Flexible Particularly in high capacity slings4 Better protection against abrasions and cuts Load bearing yarns are not in direct contact with the load or other rigging Better protection against UV degradation Load bearing yarns are protected from UV damage by the outer cover Available in capacities up to 100,000 and larger

37 Wire Rope Slings Advantages Low cost Heat resistant Flexibility Reusable components Hardware Durability Disadvantages Internal corrosion Not repairable Heavy

38 Wire Rope is a Machine A wire rope is a machine, by dictionary definition: An assemblage of parts that transmit forces, motion, and energy one to another in some predetermined manner and to some desired end. A typical wire rope may contain dozens of individual wires which are formed and fabricated to operate at close bearing tolerances one to another. When a wire rope bends, each of its many wires slides and adjusts in the bend to accommodate the difference in length between the inside and the outside bend. The sharper bend, the greater movement.

39 Wire Rope is a Machine All components of a wire rope MUST move for the rope or sling to reach it s full capacity This is important when performing inspections!

40 Does This Machine Look Healthy?

41 Broken Wires.. O-My! OSHA Recognized limits on the number of broken wires include: For strand-laid and single-part slings, 10 randomly distributed broken wires in one rope lay, or 5 broken wires in one strand in one rope lay. For cable-laid slings 20 broken wires per lay. For six-part braided slings 20 broken wires per braid. 4: For eight-part braided slings, 40 broken wires per braid

42 Broken Wires.. O-My!

43 Complicated! What type of wire rope Stranded, Cable Laid, What type of break Valley, Crown, Fatigue What s the lay length What type of crane Is there other damage

44 Keep It Simple Broken wires are concerning! Most commonly they are the result of some type of abuse Generally are accompanied by other damage seen or unseen If you spot broken wires: Take the sling out of service Have it evaluated

45 Other Wire Rope Removal Criteria Severe localized abrasion or scraping, Kinking, crushing, bird caging, or any other damage to the rope structure, Evidence of heat damage, Crushed, deformed, or worn end attachments, Severe corrosion of the rope, end attachments or fittings, Missing or illegible sling identifications, and Other conditions that cause doubt as to continual safe use of the sling.

46 Chain Slings Advantages Flexibility Impact resistance Can be used in a higher temperature Completely repairable Minimum elongation Most Durable Disadvantages Heavy Moderate initial cost Marring of load Gripping / Slipping

47 Chain - Types For Lifting Alloy Steel Grade 80 Grade 100 Grade 120 NOT for Lifting Grade 30 Grade 40/43 Grade 70

48 Chain Slings - Inspection OSHA MANDATED Minimum annual Must be documented Each sling to have it s own record Can be repaired

49 Chain Slings Removal Criteria Per ASME B30.9 Missing or illegible sling identification tag Cracks or breaks Excessive wear, nicks, or gouges Stretched chain links or components Bent, twisted, or deformed chain links or components Evidence of heat damage Excessive pitting or corrosion Lack of ability of chain or components to hinge freely Weld splatter Other conditions, including visible damage, that cause doubt as to the continued use of the sling

50 Manual Hoists Types Lever operated Hoists Leverhoist Come-a-ling Hand chain operated hoists Chainfall

51 Manual Hoists - Inspections OSHA (a)(6) - All overhead hoists in use shall meet the applicable requirements for construction, design, installation, testing, inspection, maintenance, and operation, as prescribed by the manufacturer Doesn t specifically address manual hoist

52 Manual Hoists - Inspections ASME Frequent inspection visual inspections performed by the operator or other designated personnel and are to be performed daily to monthly and prior to each use. Periodic inspections are visual inspections to be performed every 3 months to 1 year by and designated person who records conditions to provide a basis for continuing evaluations of the hoist

53 Manual Hoists Operating Practices All chain used in manual hoists are made specifically for that hoist. No other chain will meet the required dimension to operate safely or correctly in the lift wheels or pockets. The chain could climb out of the pocket and jam the hoist. Load chain shall never come in contact with the load being lifted. Only use alloy chain sling for lifting. Before using check lower block on reeved hoists to make sure it is not capsized or flipped. A small amount of lubricant will greatly increase the life of the load chain

54 Manual Hoist Rigging

55 Well Maintained Machine?

56 Proper Use?

57 Below the Hook Lifters

58 Standards ASME B30.20 Below the Hook Lifting Devises Complete Standard Addresses: design, fabrication, marking/tagging, inspection and maintenance General Industry Slings / Rigging Says Virtually Nothing Construction Slings / Rigging Basically says special lifters must be proof tested Interpretation letters invoke the general duty clause and reference ASME B30.20

59 Inspections - ASME Pre-Shift Minimum - Annual Dated inspection reports shall be made on critical items such as those listed in para Records should be available to appointed personal for each periodic inspection and when the lifter is either modified or repaired

60 Below The Hook Lifters Homemade = BAD

61 Below the Hook Lifters Generally speaking homemade lifters can not simply be certified Takes more than a load test 5 : 1 min design factor Weld specifications Engineering review

62 Below the Hook Lifters

63 Overhead Cranes & Hoists Bridge Cranes Jib Cranes Monorail Cranes Stationary Hoisting Equipment

64 Bridge Crane Double Girder Top Running

65 Jib Cranes

66 Wall Mounted Jibs Correct Mounting of Wall Mounted Jibs is Critical! The building and column must be considered

67 Monorail Cranes

68 Bridge Crane - Inspections OSHA Pre-Shift/Use Inspections (daily) Monthly Inspections of Wire Ropes and Hooks Documented Periodic Inspections Minimum annually Must be documented

69 Bridge Crane - Inspections (b) - General requirements (b)(1)Application. This section applies to overhead and gantry cranes, including semigantry, cantilever gantry, wall cranes, storage bridge cranes, and others having the same fundamental characteristics. These cranes are grouped because they all have trolleys and similar travel characteristics.

70 Jib & Monorail While only applies to overhead bridge/gantry cranes OSHA made it clear in a 1991 letter of interpretation that they will apply the ASME/ANSI B30 national consensus standards where no OSHA standard exists. Below is an excerpt from that letter: While OSHA as yet has no standard of its own covering monorail systems and underhung cranes, under Section 5(a)(1) (the general duty clause) of the Occupational Safety and Health Act all employers have a legal responsibility to provide safe and healthful workplaces for their employees. OSHA's policy is that the general duty clause requires employers to comply with safety standards recognized in the industry, such as ANSI B30.11

71 Jib & Monorail - Inspections ASME Pre-Shift/Use Inspections (daily) Monthly Inspections of Wire Ropes and Hooks Documented * Periodic Inspections Minimum annually Must be documented

72 Daily Inspections are Very Simple Run The Crane Look Listen Pendant Controller Wire Rope Hook Upper Limit Lower Limit

73 Pendant Controller

74 Upper Limit Switch MUST be checked every shift Pain in the butt Failure causes the most damage Many times a dropped load!

75 Monthly Hook, Wire Rope or Chain Time to get up close and personal Chain / Wire Rope Inspections can not be done from the floor! Need to inspect the entire length Particularly the top and bottom Inspector Needs to Be Trained We spend 6 hours on the subject with our new service techs As well as several months OJT

76 Close up inspection required!

77 Close up inspection required!

78 Other Considerations Train your operators Daily Equipment Inspections Proper Load Handling Safe Operation Location of Emergency Disconnects Required by OSHA ALL operators must know where they are

79 Mitigate The Danger What we can control Training Inspections Proper storage Proper equipment Proper maintenance Lift Planning Know the weight of your load Provide the correct rigging gear